Using cost-calculating tools in conjunction with an AWIM system can give companies a baseline against which they can measure and validate any improvements they make rather than analyzing them through manual time-study efforts. This allows managers to track, in real time, whether the changes they’ve implemented are actually benefiting the welding operation. For example, an AWIM system can track deposition rates to help determine how much more efficient a welding opera- tion could be using a different filler metal, such as metal-cored wire—a product capable of increasing deposition rates and trav- el speeds, typically by 15–20% or more. These systems can then examine arc-on times and compare the entire cycle time of the job with old cycle times to calculate exactly how much more productive the operation is after such a filler metal conversion. It is important to analyze all of these factors, as there could be scenarios where higher deposition rates will actually result in less arc-on time because of the faster travel speeds. In this scenario, the goal would be to maintain the current arc-on time along with the higher deposition rates that can yield lower cycle times and increase productivity.
Setting Parameters and Gaining Efficiencies AWIM systems can help companies improve the overall quality of their products by ensuring welding operators fol- low the proper standards and guidelines. They can monitor and help control heat input, reduce distortion, and minimize over- or under-welding conditions by tracking weld duration and deposition, thereby reducing labor costs and filler metal waste, and improving throughput.
For instance, if a welding operator needs to make a 10" (254-mm) weld, one can calculate—based on the size, length, and wire-feed speed—how much time that weld should take to complete. Management can program the AWIM system to give welding operators a window of time to complete the weld so they are not above or below the prescribed duration. Doing this ensures that the weld is in place and that the weld is prop- erly sized. These systems also help prevent under- or over- welding by monitoring the weld deposit. Since some welding procedures allow for a wire-feed speed range, and operators
An AWIM system can track deposition rates to help determine how much more efficient a welding operation could be using a different filler metal, such as metal-cored wire.
might prefer running at different wire feed speeds within that range, a company could set the system to track deposition instead of tracking duration and achieve the same result. AWIM systems safeguard against mistakes by providing welding operators with guided sequences that take them step- by-step through the entire process. Welding operators must finish each weld, in the proper order, before proceeding to the next. The systems can alert welding operators to missed welds, incorrect sequences and over- or under-welding, and when they have violated a predetermined welding parameter. Any nonconforming weld or part can be flagged and an alert can be immediately sent to the proper department to address the issue before the part leaves the weld- ing cell. This feature allows for immediate quality control and the quick correction of errors. Management can also set
AWIM systems to automatically
select the proper program and predetermine the set of welding parameters an operator should use for each weld throughout the process, which may be different from one weld to the next. This saves welding operators’ time by automatically changing the programs and parameters throughout the welding proce- dure to the prescribed values. It also prevents the operator from having to walk back to the machine to make changes manually.
Boosting the Bottom Line In addition to determining how to improve arc-on time
and throughput, AWIM systems can track costs to help companies become more profitable. These systems can cre- ate detailed reports on part counts, arc-on time, equipment efficiency and more. Using the information gathered by these sophisticated systems, companies are better armed to make decisions about how to improve their process, reduce costs and drive continuous improvement. In the end, AWIM systems provide a way to analyze the bigger picture within the welding operation, so managers and owners can optimize the entire process and confirm that their efforts are, indeed, saving money and time. They also empower welding operators to take greater ownership of the operation and help improve the company—and, ultimately, the bottom line.
61 — Motorized Vehicle Manufacturing 2015
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